In this paper, a low temperature sputtered AlN cap-layer p-GaN HEMT with high gate breakdown and improved reliability is realized. XPS test shows that the valence band offset of p-GaN and low-temperature magnetron sputtered AlN is 1.2 eV, which successfully suppresses the gate leakage current and greatly improves the gate reliability. Low capacitance–voltage hysteresis and small pulsed threshold voltage shift predict good AlN/p-GaN interface quality. The threshold voltage of the AlN/p-GaN HEMT is improved from 0.61 V to 0.82 V compared to the conventional p-GaN HEMT with tungsten Schottky gate (W/p-GaN HEMT), the DIBL decrease from 34.4 mV/V in W/p-GaN HEMT to 1.1 mV/V in AlN/p-GaN HEMT. The gate forward and reverse leakage is significantly suppressed, and the gate forward breakdown voltage is improved to 17 V. The gate operating range is improved from 7 V to 12 V, and the ID/IG under saturation state is improved from 104 to 107. In addition, a smaller on-resistance of 67.5 Ω·mm was obtained, which is 15.3 % lower than that of the W/p-GaN HEMT, minimizing on-state loss. The gate leakage mechanism of the AlN/p-GaN HEMT is mainly dominated by the PF emission in the medium gate voltage range. Based on this leakage mechanism, the maximum forward VG for a ten-year lifetime was extracted as 6.8 V at room temperature at a failure level of 63.2 % for the AlN/p-GaN HEMT, while this value for W/p-GaN HEMT is 5.4 V. In addition, the AlN cap layer attenuates the depletion region of metal/p-GaN by the gate Schottky metal, which keeps the GaN channel better depleted, thus keeping a higher off-state breakdown voltage. These results demonstrate the good potential of magnetron sputtering AlN as a low-cost, methodologically simple growth method for the commercial use of p-GaN HEMTs.
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